Fiber Enforced Thin Brick Sheet and Process

ABSTRACT

A fiber enforced sheet for use as a wall or floor covering which comprises of adhered thin bricks bonded to a fiber-reinforced, backing layer. Thin brick is adhered to the fiber enforced sheet. The fiber enforced backing increases strength and rigidity to the thin brick during handling, and installation permits the thin bricks to be adhered to proper specification and spacing to be cut using ordinary tile or thin brick tools.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to fabricated thin brick sheets for use as wall or floor coverings and a process for manufacturing such sheets. The invention is a veneer, one layer of which comprises of an array of glued or adhesive applied thin bricks.

2. The Prior Art

Thin brick has long been a highly desired backing material for walls and floors, for interior and exterior, and the like. It is attractive, durable, waterproof, and fireproof. Thin bricks are available in a wide variety of sizes, shapes, colors, patterns, textures, and surface finishes. They are uniquely suited to a variety of applications ranging from decorative accents in the homes to complete commercial exterior finishes.

Thin brick per se is relatively inexpensive, being made essentially from clay minerals fired at high temperature. Not so its installation. The conventional construction of a thin brick wall, for example, begins with the installation of metal lath over a vapor barrier secured sheathing. Next, a scratch coat of mortar is applied to the lath followed by an accurately leveled mortar bed for the thin brick. Should the scratch coat be uneven, a separate, additional leveling layer of mortar may be required. When using adhesive brick are set one by one then grouted using mortar applied between thin brick. Individual thin bricks must be cut using special equipment and tools to fit them to spaces requiring less than a full thin brick or to fit them around fixtures and the like.

Thin brick setting is a skilled occupation, commanding high wages. The level of skill required, and the time-consuming nature of conventional thin brick installation render the process very expensive. Unfortunately, due to the high cost of thin brick installation, some builders have attempted installation shortcuts in a misguided effort to save money. Improper installation techniques frequently result in expensive repairs for the homeowner or general contractor.

Given this situation, it is not surprising to find a number of proposed solutions to the problem in the prior art. The concept of a prefabricated thin brick sheet which would not require any thin brick setting at the installation site has long been considered. However, the thin brick sheets previously described have all proved unsatisfactory for reasons such as insufficient strength, excessive weight, complexity of installation, and high labor cost. And none have met with commercial success to any significant extent.

Thus, it will be appreciated that the prefabricated thin brick sheets known in the art prior to this disclosure all relied on a core part, commonly of steel, plastic, foam, or a relatively thick backing layer to impart some measure of structural strength and rigidity to the sheets. These cores substantially increase the thickness of the sheets, and this in turn necessitates special mounting hardware for installation.

SUMMARY OF THE INVENTION

The present invention comprises a thin, lightweight thin brick sheet which greatly simplifies and reduces the cost of installing thin brick walls, floors, and the like. The invention further comprises a method of making such a sheet and or installation.

The thin brick sheets of the invention include a plurality of thin bricks pre-assembled and mounted on a fiber enforced sheet. The spaces between the thin bricks are filled with grout to seal these spaces against moisture, etc. The term “grout” should be understood to include both the conventional thin, cementitious mortar used for filling joints in masonry as well as chemicals that solidify, such as polyurethanes, room temperature vulcanizing silicones, other elastomers, plastics, and the like. The sheets normally feature a regular pattern of substantially rectangular thin bricks in a side-by-side, laterally spaced rectangular array; however, a wide variety of thin brick shapes and trim pieces are contemplated.

The thin bricks of the invention are preferably thinner and lighter than common bricks. Thus, the thin bricks will generally be greater than 0.125 inch thick, and less then 3 inches. The light weight of the thin bricks makes it possible for relatively large sheets of such thin bricks to be assembled and handled with comparative ease. The fiber enforced sheet may be made of a variety of materials. The sheets themselves will normally be flexible, but it is important that they be substantially non-stretchable. This quality is important because the backing and backing sheets on each thin brick sheet co-act to render the sheet rigid enough to be readily handled and worked.

Working of the thin brick sheets for example, may include cutting or drilling with tools such as razor knifes, table saws, and the like. After the thin bricks are adhered the sheets can then be cut between bricks using just a razor knife. This enables such working to be carried out with very little breaking, chipping, or other damage to the thin brick elements.

Applying thin brick sheets over exterior require cementitious adhesive sealing all seams and applying a roll on water barrier following all building codes. When applying thin brick sheets over interior, a thinset, mastic or equivalent will be required.

It will be apparent that the sheets be strong, substantially non-stretchable, substantially water-resistant, chemically stable, and capable of being bonded to the thin bricks as well as to plaster, wood, cement, block, drywall sheets [gypsum board; sheetrock], etc. with conventional construction adhesives. As mentioned above, woven fiberglass fabric is an especially preferred component of the backing sheets; however, other fabrics or reinforcing agents considered suitable include polyester, graphite, aramid, or carbon fibers, or any combination thereof. Especially preferred is a fiberglass combination.

Synthetic adhesives suitable for impregnating the backing sheets include unsaturated fiberglass, phenolic, epoxy, and silicone adhesives.

In general, the adhesives should possess the same general characteristics as the backing sheets. The cured adhesive should be strong, substantially non-stretchable, substantially impervious to moisture, function as an adhesive to bond the back surfaces of the thin bricks to the sheet, and be capable of being bonded to common wall surfaces and the like with conventional construction adhesives such as thin set or mastic and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 Is a cross-sectional view of fiber enforced thin brick sheets of the said invention.

FIG. 2 Cut thru order of fiber enforced thin brick process.

FIG. 3 Is a cross-sectional view of corner thin brick using fiber enforced thin brick sheets in the process of the said invention.

FIG. 4 View of an example layout of the corner thin brick sheets of said invention showing application arrangement and edges of such a sheet.

DETAILED DESCRIPTION OF THE DRAWINGS

The invention will best be understood by referring to the drawings.

FIG. 1 shows a portion of a thin brick sheet in cross section. Individual thin brick elements (5) are supported by adhesive (6) on a fiber-reinforced backing layer (7). Anti-adhesive paper on back of thin brick sheets for separation and adhesive release (8).

FIG. 2 schematically illustrates a cut thru fabricated thin brick sheets. Thin layer of anti-adhesive paper to prevent bonding of the backing layer adhesive (9). Reinforcing fabric (10) for the backing layer. Adhesive at a high temperature is then impregnated or applied to either brick or fiber-reinforced backing layer (11). Individual thin brick elements (12).

FIG. 3 schematically illustrates corner thin brick sheets. Thin layer of anti-adhesive paper to prevent bonding of the backing layer adhesive that is curved in the same position of a typical thin brick corner (13). Reinforced fabric sheet that is curved in the same position of a typical thin brick corner (14). Adhesive at a high temperature is then impregnated or applied to either corner brick or fiber-reinforced backing layer (15). Thin corner brick positioner (16) helps in the proper spacing and alignment process.

FIG. 4 shows in detail the layout of an optional embodiment of the thin brick sheets and corner sheets of the present invention. Corner sheets are typically applied first (17) were brick are placed opposite of each other. The thin bricks are staggered in typical brick patterns (18) and fiber-reinforced backing layer extends beyond the thin brick elements on one edge of the sheet (19), while on the opposite edge the thin brick elements overhang the fiber-reinforced backing layer by an equal distance (20). This permits abutting thin brick sheets to be joined together in such a way that the joint between bricks are the proper space to adjacent thin brick sheets.

SUMMARY

Alternatively, the sheets of the present invention may be manufactured individually in multiple sizes. Thin bricks are placed face down or face up within the confines of a frame designed to hold the loose thin bricks in a rectangular array. Gaps are left between the edges of adjacent thin bricks to permit the subsequent insertion of grout as is well known in the art.

Reinforcing fabric for the backing layer is then placed over the exposed rear surfaces of the thin brick elements in the array. A adhesive is then applied to the fabric first or brick first, saturating it and extending through it to contact the thin bricks or sheets. As the adhesive cures it bonds the backing layer to the thin bricks. This process may be accelerated by the application of heat to raise the temperature of the adhesive/catalyst mixture thereby increasing its cure rate.

When the adhesive of the backing layer has substantially cured, the backing layer with the thin brick elements bonded to it is inverted, exposing the front face of the thin brick elements. Grout or mortar other suitable or alike material is applied to the spaces between the thin bricks.

In use, the thin brick sheets are mounted to conventional floor or wall surfaces using construction adhesives of the type previously mentioned.

While one specific embodiment of the invention has been disclosed herein, it should be understood that this disclosure is made by way of illustration rather than limitation. Numerous changes may be made by those skilled in the art, particularly with reference to the dimensions, materials and configuration disclosed herein. Changes of this nature would not depart from the spirit of the invention or the scope of the appended claims. 

What is claimed:
 1. A fiber enforced thin brick sheet comprising of glass filaments. a semi-flexible, substantially non-stretchable, comprise glass filaments. A thin brick layer comprising of thin bricks bonded on their back surfaces to the baking layer,
 2. A fiber enforced thin brick sheet. Thin brick comprising of multiple types of brick; clay, cast brick, wire cut, and the like all formed or cut to be thin brick applied wherein the backing layer is a fiber-reinforced sheet.
 3. A fiber enforced thin brick sheet comprising of brick varying in multiple ways in which you lay individual bricks showing a variety of patterns or bonds. Different combinations of brick bond examples; running bond, stack bond, English bond, and the like.
 4. A fiber enforced thin brick sheet as recited in claim 2 wherein the backing layer is a fiber-reinforced sheet.
 5. A fiber enforced thin brick sheet as recited in claim 4 wherein the adhesive is selected from the group consisting of bonding adhesive, epoxy adhesive, and silicone adhesive.
 6. A fiber enforced thin brick sheet as recited in claim 4 wherein the reinforcing fiber is selected from one or more members of the group consisting of, graphite fibers, aramid fibers, carbon fibers, and fiberglass fibers.
 7. A fiber enforced thin brick sheet as recited in claim 6 wherein the fibers are woven into a grid like fabric.
 8. A fiber enforced thin brick sheet as recited in claim 1 wherein the backing layer is poly fiber.
 9. A fiber enforced thin brick sheet as recited in claim 1 wherein the backing layer is formed of spun bonded glass filaments.
 10. A thin brick sheet as recited in claim 1 wherein the fiber enforced thin brick sheets overhang on one edge while on opposing end the thin brick overhang the backing layer as to interlock adjoining sheet.
 11. A fiber enforced thin brick sheet as recited in claim 2 wherein the adhesive of the backing layer bonds the thin bricks of the thin brick layer to the backing layer.
 12. A fiber enforced thin brick sheet as recited in claim 1 wherein the thin bricks are spaced from one another and the spaces between adjacent thin bricks in the thin brick layer are filled with mortar or grout.
 13. A fiber enforced thin brick sheet as recited in claim 12 wherein the spaces between adjacent thin bricks in the thin brick layer are filled with a cement base material.
 14. A fiber enforced thin brick sheet as recited in claim 13 wherein the adhesive is silicone based product.
 15. A process for producing a fiber enforced thin brick sheet comprising of adhered individual thin bricks into a rectangular array, leaving spaces of approximately ¼ inch to ¾ inch between adjacent thin bricks
 16. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the reinforcing fabric is made of fibers selected from the group consisting of fiberglass fibers, graphite fibers, aramid fibers, carbon fibers, and poly fibers.
 17. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the adhesive is selected from the group consisting of unsaturated fiberglass adhesive, phenolic adhesive, epoxy adhesive, and silicone adhesive.
 18. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the thin brick adhesive is an elastomeric or silicone base adhesive.
 19. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the thin brick grout is cement base.
 20. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the thin brick grout is sand based.
 21. A process for producing a fiber enforced thin brick sheet as recited in claim 15 wherein the substantially non-stretchable fiber enforced thin brick sheet has holes ranging from 1/16 inch to 2 inches for adhesive bonding.
 22. A process for producing a fiber enforced thin brick sheet as recited in claim 21 wherein the fiber enforced mesh sheet ranging from 2.5 oz to 30 oz is designed to hold the weight of multiple thin brick.
 23. A processes of applying a thin brick wherein the curing of the adhesive is accelerated by the application of heat.
 24. A processes of applying a thin brick wherein the adhesive is of high heat thus accelerating the curing time.
 25. A continuous process for producing a fiber enforced thin brick sheet on an endless belt, which were thin brick are applied using adhesive: (a) feeding a reinforcing fabric onto the endless belt; (b) passing the reinforcing fabric on the endless belt through an impregnating zone wherein the fabric is saturated with a high heat adhesive; (c) passing the adhesive-saturated fabric through a thin brick application zone wherein array of thin bricks are applied to the adhesive-saturated fabric; (d) passing the adhesive-impregnated fabric with thin bricks through an oven which raises the temperature of the adhesive to increase its curing rate and to bond the thin bricks to the backing layer comprising of fabric reinforced glue adhesive; (e) moving the fiber enforced thin brick sheet to a cutting zone wherein the sheet is cut into sections of desired size. Optional grouting: (1) moving the substantially cured backing layer with bonded thin bricks through a grouting zone wherein material is deposited in the spaces between the edges of adjacent thin bricks on the sheet; (g) moving the substantially cured backing layer with bonded thin bricks through a cleaning zone wherein water, air, or cleaning solution is applied.
 26. A fiber enforced sheet of thin bricks for use as a wall surface or the like which comprises: a flexible, substantially non-stretchable, backing sheet; a plurality of thin bricks bonded on their back surfaces to said backing sheet in a side-by-side, laterally spaced array; a filler grout between said thin bricks.
 27. The sheet of claim 26 in which said fiber enforced backing is adhered to brick using adhesive.
 28. The sheet of claim 27 including a contact adhesive between said backing sheet and the back surfaces of said thin bricks.
 29. The sheet of claim 26 in which said backing sheet is a fabric impregnated with a synthetic adhesive.
 30. The sheet of claim 26 in which said thin bricks are rectangular, and said sheet array is a rectangular also.
 31. A process for making a anti-adhesive paper enforced sheet for which comprises: non bonding the back surfaces of a plurality of thin bricks to a substantially non-stretchable, backing sheet covering the back surfaces of said thin bricks with a flexible, sheet used for releasing of adhesive from said sheets.
 32. A fiber enforced sheet of thin bricks for use as a wall surface or the like which comprises: a flexible, substantially non-stretchable, backing sheet; a plurality of thin brick corners bonded on their back surfaces to said backing sheet in a stacked vertically spaced array; a filler grout between said thin bricks.
 33. The sheet of said corner brick of 32 in which corner brick are bonded to fiber enforced backing. Said fabric is bent at an angle that of the matching brick.
 34. The process of manufacturing fiber sheets bonded to corner brick using adhesive bonders.
 35. The process of manufacturing fiber sheets bonded to corner or brick bonded using adhesive bonders. Corner thin brick is adhered in such a way as to give ¼ inch to ¾ inch exact spacing between corner brick.
 36. A process for producing a fiber enforced thin brick sheet on assembly process of hand gluing individual thin brick to fiber sheet using a grid, template or stencil.
 37. A process for producing a fiber enforced corner thin brick sheet on assembly process of hand gluing individual thin brick to fiber sheet using a grid, template or stencil.
 38. A process of adhering thin brick to fiber enforced sheets using adhesive that has high elevated temperatures thus curing quickly so as to facilitate manufacture of the thin brick sheets in a timely way.
 39. A process of adhering fiber enforced sheets to floor or wall using an adhesive that penetrates thru said fiber enforced sheets providing a grid like bonding pattern for grout or mortar.
 40. A process of adhering fiber enforced sheets to floor or wall using an adhesive that penetrates thru said fiber enforced sheets and adheres to majority of exposed thin brick thus helping bond brick to floor or wall.
 41. A process of adhering fiber enforced sheets to floor or wall. Adhesive applied to wall or floor followed by applying fiber enforced sheet thus enabling adhesive to penetrate thru fiber enforced sheet to help hold or cling to wall or floor surfaces. 